Hydrogen-processing assemblies and hydrogen-producing systems and fuel cell systems including the same

Abstract

Hydrogen-processing assemblies, components of hydrogen-processing assemblies, and fuel-processing and fuel cell systems that include hydrogen-processing assemblies. The hydrogen-processing assemblies include a hydrogen-separation region housed within an enclosure. The enclosure includes a body portion having an opening and at least one flange extending adjacent the opening. The enclosure further includes an end plate positioned at least partially within the opening. The at least one flange of the body portion engages the end plate and retains the end plate within the opening. The at least one flange may retain the end plate in a position to apply compression to the hydrogen-separation region. The hydrogen-processing assemblies may further include at least one weld or other seal that secures the at least one flange to the end plate and/or defines a fluid tight interface between the body portion and the end plate.

1 . A hydrogen-processing assembly, comprising:
 a hydrogen-separation region including at least one hydrogen-selective membrane, wherein the hydrogen-separation region is adapted to receive a mixed gas stream containing hydrogen gas and other gases and to separate the mixed gas stream into a permeate stream and a byproduct stream, wherein the permeate stream has at least one of a greater concentration of hydrogen gas and a lower concentration of the other gases than the mixed gas stream, and further wherein the byproduct stream contains at least a substantial portion of the other gases; and   an enclosure defining an internal volume including a mixed gas region and a permeate region separated by the hydrogen-separation region, the enclosure comprising:
 a body portion including an opening and at least one flange extending adjacent the opening; 
 an end plate positioned at least partially within the opening and including an external surface, wherein the at least one flange engages the external surface of the end plate and retains the end plate within the opening; 
 a seal defining a fluid tight interface between the body portion and the end plate; 
 at least one input port through which a fluid stream is delivered to the enclosure; 
 at least one product output port through which the permeate stream is removed from the permeate region; and 
 at least one byproduct output port through which a byproduct stream is removed from the mixed gas region. 
   
   
   
       2 . The assembly of  claim 1 ,
 wherein the fluid stream is the mixed gas stream containing hydrogen gas and other gases and is delivered to the mixed gas region;   wherein the at least one hydrogen-selective membrane includes a first surface adapted to be contacted by the mixed gas stream and a permeate surface generally opposed to the first surface; and   wherein the permeate stream is formed from a portion of the mixed gas stream that passes through the membrane to the permeate region of the internal volume.   
   
   
       3 . The assembly of  claim 1 , wherein the assembly further comprises a hydrogen-producing region;
 wherein the fluid stream is a feed stream and is delivered to the hydrogen-producing region;   wherein in the hydrogen-producing region, the feed stream is chemically reacted to produce hydrogen gas therefrom in the form of the mixed gas stream containing hydrogen gas and other gases, and wherein the mixed gas stream is delivered to the mixed gas region of the internal volume;   wherein the at least one hydrogen-selective membrane includes a first surface adapted to be contacted by the mixed gas stream and a permeate surface generally opposed to the first surface; and   wherein the permeate stream is formed from a portion of the mixed gas stream that passes through the membrane to the permeate region of the internal volume.   
   
   
       4 . The assembly of  claim 1 , wherein the seal includes a weld. 
   
   
       5 . The assembly of  claim 1 , wherein the seal includes a fillet weld between the at least one flange and the end plate. 
   
   
       6 . The assembly of  claim 1 , wherein the seal includes a seal weld. 
   
   
       7 . The assembly of  claim 1 , wherein the seal includes a lap weld between the at least one flange and the end plate. 
   
   
       8 . The assembly of  claim 1 , wherein the fluid tight interface is free of groove welds. 
   
   
       9 . The assembly of  claim 1 , wherein the seal includes a weld extending the entire length of the fluid tight interface, at least a portion of the weld including a fillet weld between the at least one flange and the end plate. 
   
   
       10 . The assembly of  claim 1 , wherein the end plate includes a peripheral region corresponding to a perimeter of the opening. 
   
   
       11 . The assembly of  claim 10 , wherein a portion of the peripheral region extends outside of the opening. 
   
   
       12 . The assembly of  claim 10 , wherein no portion of the peripheral region extends outside of the opening. 
   
   
       13 . The assembly of  claim 1 , wherein the opening includes three or more sides, and the at least one flange includes at least one flange extending adjacent each of the three or more sides of the opening. 
   
   
       14 . The assembly of  claim 1 , wherein the at least one flange extends adjacent the opening within a plane generally parallel to the opening. 
   
   
       15 . The assembly of  claim 1 , wherein the at least one flange extends adjacent the opening at an acute angle relative to an inside surface of an adjacent wall of the body portion. 
   
   
       16 . The assembly of  claim 1 , wherein the at least one flange includes:
 a first portion extending adjacent the opening at an obtuse angle relative to an inside surface of an adjacent wall of the body portion; and   a second portion extending from the first portion within a plane generally parallel to the opening.   
   
   
       17 . The assembly of  claim 1 , wherein the at least one flange extends adjacent the opening at an obtuse angle relative to an inside surface of an adjacent wall of the body portion. 
   
   
       18 . The assembly of  claim 17 , wherein the obtuse angle is in the range of 100 and 170 degrees. 
   
   
       19 . The assembly of  claim 1 ,
 wherein the fluid stream is the mixed gas stream that is delivered to the mixed gas region;   wherein the hydrogen-separation region includes a plurality of spaced-apart hydrogen-selective membranes, each membrane having a first surface adapted to be contacted by at least a portion of the mixed gas stream and a permeate surface generally opposed to the first surface; and   wherein the permeate stream is formed from a portion of the mixed gas stream that passes through the membrane to the permeate region of the internal volume.   
   
   
       20 . The assembly of  claim 1 ,
 wherein the fluid stream is a mixed gas stream containing gas and other gases and is delivered to the mixed gas region;   wherein the hydrogen-separation region includes at least one membrane envelope formed from a pair of hydrogen-selective membranes;   wherein each membrane includes a first surface adapted to be contacted by the mixed gas stream and a permeate surface generally opposed to the first surface;   wherein the pair of membranes are spaced apart from each other with their respective permeate surfaces generally facing each other to define the permeate region in the form of a harvesting conduit extending between the respective permeate surfaces; and   wherein the permeate stream is formed from at least a portion of the mixed gas stream that passes through the pair of hydrogen-selective membranes to the harvesting conduit, with at least a portion of the mixed gas stream that does not pass though the membranes forming at least a portion of the byproduct stream.   
   
   
       21 . The assembly of  claim 1 , wherein the at least one flange compresses the hydrogen-separation region between the body portion and the end plate. 
   
   
       22 . The assembly of  claim 21 , wherein the hydrogen-separation region includes a plurality of spaced-apart hydrogen-selective membranes, each membrane having a first surface adapted to be contacted by at least a portion of the mixed gas stream and a permeate surface generally opposed to the first surface. 
   
   
       23 . The assembly of  claim 1 ,
 wherein the body portion further includes a second opening and at least a second flange extending adjacent the second opening;   wherein the enclosure further comprises:
 a second end plate positioned at least partially within the second opening, wherein the at least a second flange engages the second end plate and retains the second end plate within the second opening; and 
 a second seal defining a fluid tight interface between the body portion and the second end plate. 
   
   
   
       24 . The assembly of  claim 23 , wherein the first and second flanges compress the hydrogen separation region between the end plate and the second end plate. 
   
   
       25 . The assembly of  claim 1 , in combination with a fuel cell stack adapted to receive at least a portion of the permeate stream. 
   
   
       26 . The assembly of  claim 1 , in combination with a hydrogen-producing region adapted to produce the mixed gas stream to be delivered to the mixed gas region of the enclosure. 
   
   
       27 . The assembly of  claim 26 , wherein the hydrogen-producing region includes at least one reforming catalyst bed. 
   
   
       28 . The assembly of  claim 27 , wherein the hydrogen-producing region is external to the enclosure. 
   
   
       29 . The assembly of  claim 27 , wherein the hydrogen-producing region is internal to the enclosure. 
   
   
       30 . The assembly of  claim 27 , in further combination with a fuel cell stack adapted to receive at least a portion of the permeate stream and to produce an electric current therefrom. 
   
   
       31 . A hydrogen-processing assembly, comprising
 a hydrogen-producing region adapted to produce a mixed gas stream containing hydrogen gas and other gases from at least one feed stream, wherein hydrogen gas forms a majority component of the mixed gas stream;   a hydrogen-separation region including a membrane assembly with at least a plurality of spaced-apart hydrogen-selective membranes, each membrane having a first surface adapted to be contacted by at least a portion of the mixed gas stream and a permeate surface generally opposed to the first surface, wherein the membrane assembly is adapted to separate the mixed gas stream into a permeate stream and a byproduct stream, wherein the permeate stream has at least one of a greater concentration of hydrogen gas and a lower concentration of the other gases than the mixed gas stream, and further wherein the byproduct stream contains at least a substantial portion of the other gases; and   an enclosure defining an internal volume including a mixed gas region and a permeate region separated by the hydrogen-separation region, wherein the enclosure houses the hydrogen-producing region, the enclosure including:
 a body portion including an opening and at least one flange extending adjacent the opening; 
 an end plate positioned at least partially within the opening wherein the at least one flange engages the end plate and retains the end plate within the opening, wherein the at least one flange compresses the hydrogen-separation region between the body portion and the end plate; 
 a seal securing the at least one flange to the end plate; 
 at least one input port through which at least one feed stream is delivered to the hydrogen-producing region; 
 at least one product output port through which the permeate stream is removed from the permeate region; and 
 at least one byproduct output port through which a byproduct stream is removed from the mixed gas region; 
   wherein in the hydrogen-producing region, the feed stream is chemically reacted to produce a mixed gas stream containing hydrogen gas and other gases, wherein hydrogen gas forms a majority component of the mixed gas stream, and further wherein the mixed gas stream is delivered to the mixed gas region of the internal volume.   
   
   
       32 . The assembly of  claim 31 , wherein the seal forms a fluid tight interface between the body portion and the end plate.